Note: Descriptions are shown in the official language in which they were submitted.
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VARIABLE POWER ZONE SPACER FABRIC s BACKGROUND OF THE IM/E4VTION
1. Field of the Invention 10 =
The present invention relates to a spacer fabric for a garment. More
particularly, the present invention relates to a spacer fabric for a garment
having
eNasticized yams seiectivety knitted into the spacer fabric of a gamient Stfti
more
particularly, the present invention refates to a spacer fabric for a garment
having
15 selective{y andlor intermittently knitted In etasticlzed yams to cxeate
zones of
predetermined and varlabte moduii of efasticity throughout the gamient.
2. Related Art 20
Garments, partlcularly undergarments, must be designed to accommodate
a variety of functions, such as, providing necessary oomfort. support and
modesty. In addfbon these expected functfons, the undergarment also offer
support In desired locations and be lightweight and aesthettcafiy appeating.
25 Consumers expect these attdbutes In a singte undergarment without
compromising on affordabifi[y. For manufactun3rs to satisfy their consumers,
the
desired attributes must be balanced against productlon oosts In onierto
produce
an undergarment that Is competitiwe In the market 30 For example, brassieres
are often manufactured In the lamination or cut-
and-sew manner to provide areas of distinct properties. Vartous pfeces of
fabric
can be made of dtfferent imits, dPffenent yams, eta that are taminated or sewn
together to form ihe brassiere. However, such methods for making brassieres
can be disadvantageous because the process entails a large number of placfng
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and heating steps or manual ccrtting and sewing operations that are time
Consuming and costly.
Alternatively, manufactures often use ckcuiar knitting to produce cost
s effective seamless blanks, that are cut folded and sewn to quickly produce a
seamless brassiere. The circular knitting process is very efflcient; however,
different areas of support or zones cannot often be intiortwrated Into a
singEe
lightweight and comfortabie brassiere that also, offers modesty and support.
io Therefore, a need ebsts fior a dreular knttted spacer fabric that
sefectivefy
and/or intermlitentiy has knitted in speciflc yarns to create knitted zones of
predetermined and variable modui of eiasticity in a fabric that offers modesty
and
support
15 SUMMARY OF THE INVENTION
The present ]nvention provides a spacer fabric having elastictr.ed yams
selectively andlor intermittently knitfied into a facing layer of the spacer
fabric.
20 Also, the pn3sent Invention provides a dreulariy. knltted spaoer fabric
having elasticbed yams selectively and/or Intermiltently knitted into its
facing
layer and backing layer.
Further, the present invention provides a spacer fabric having varlabte
25 regions of support knitted In at predetermined zones throughout the facing
layer
and backing layer of such a fabsic.
Still further, the present Invention provides a spacer fabric that has at
least
two differtng levels of elasticity in it.s facing andlor backing layers.
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Yet further, the present Invention provides a dreulariy knit undergarment
using a spacer fabric that has at least three levels of modulus of elas6dty
selectivety knit therein.
s Yet stiU further, the present invention provides a drwlarty knit spacer
fabric having zones of dtffering elastiaty represented by dlfferent yam coiors
or a
Jacquard pattem.
Sti14 yetfurther, the present invertiton provides a circutariy lcntit spacer
fabric having zones of differing elasticity represented by yams of different
thicknesses, the dffferent thicknesses representing different moduii of
elasticity. Further stitii, the present lnventbn provides a clrcutarV kntt
spacer fabric
having zones of difflering elasticity represented by yams of different
textures.
such as a shiny texture and a mafte texture.
Also, the pmsent inventlon provides such a fabr4c that can be used as a
garment liner for support and modesty.
Further, the present inventbn provides such a fabric that can be used as a
garment or a garment component.
Still further, the present lnvention provides such a spacer fabric that can
be mokied or used in a cut-and-sew garment.
A fabrfc having a flrst surface, a second surface oppostte the first surface
and an lntenrediate surface between the first surface and the second surfaoe
is
provided. At least one of the first surface and the second surface is knftted
with
at least one elasticized yam at at least one predeteimined zone to provide a
selected zone of elasticity to at least one of the first surface or the second
surface of the fabric.
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BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and stili other objects and advantages of the present
invention will be more apparent from the following detailed explanation of the
preferned embodiments of the invention in oonnection wtth the acoompanying
drawings.
Fig. I Illustrates a schematic side view of a spacer fabric of prior art;
Fig. 2 iflustrates a schematic perspectiv+e view of a spacer fabric of the
prior art;
Fig. 3 illustrates a schematic side view of the spacer fabric of the present
Invention;
Fig. 4 iiiustrates a schematic perspective view of the spacer fabric of the
present invention;
Fig. 5 Illustrates a dose-up view of the spacer fabric of the present
2o invention;
Fig. 6 illustrates a schematic perspective view of the spacer fabric of the
present invention fomied in a brassiere;
Fig. 7 illustrates a schematic perspective view of the spaoer fabric of the
present invention having different zones of eiasticity represented by
different
coiors; and
Fig. 8 illustrates a schematic perspective view of the specer fabric of the
prosent Invention having different zones of elasticity n3presented by a
pattem,
wherein the dfffferent elements of the pattem have different modulus of
elasticity.
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DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and, In parUcular, Fig.1, there Is shown a
spacer fabric of the prior art, generaNy represented by reference numeral 10.
s Spacer fabric 1U is preferabiy a three-dimensicnaf materiai, having a facing
surface 12, a backing surface 14 and a spacer layer 16 between layers 12 and
14. Spacer layer 16 lies In a direction that Is preferably orthogonai to
facing
surface 12 and baddng surface 14. Spacer tayer 16 provides a degree of
thickness to spacer fabft 10 that wouid not otheronse exdst.
As shown in Fig. 2, prior art fabric 10 has three yam systems. A iirst yam
system 18 fosms fadng suri'ace 12, a second yam system 20 and a th9sd yam
system 22 tbat connects the first and second yam systems 18 and 20 to form [
fabrfc 10. Spacer fabric 10 is generally knitted to have a Jacquard pattem on
Is the facing layer for aesthetk: and functionai benefds.
The spacer fabric of the present Invention, as shown in Fig. 3, is generally
represented by reference numeral 50. Spacer fabrfc 50 has a facing layer 60, a
bacidng layer 70 and a spacer layer 80. Spacer layer 80 oonnects facing layer
2o 60 and baddng layer 70 together dudng the circular knitting process. Spacer
layer 80 of the present invention, Ilke that of the prior art, provides a
degree of
thickness to spacer fabric 50. Spacer fabiic 501s knltted on a oomputer
controffed circufar knitting machine, having a cyltnder and a dial, eommoniy
used
for circuiarty knitting spacer fabric.
25 Referring to Figs. 3 through 5, facing layer 60 of spacer fabric 50 has two
zones, Zone A and Zone B that each have a different modulus of eaasticity.
Zone
A has a lower moduius of eiasticity than Zone B. Zone A of facing layer 60
includes at least one non-elasticized, yarn 62. Zone B Includes at least one
norr
3o elasticized yam 62 and one siasticizsd yam 69 to increase the modulus of
the
spacer fabric 50 In Zone B. When fadng layer 60 Is knifted, yams 62 and 66
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form altemating wales 65. When backing layer 70 is lanitted, yams 64 and 68
form atternating wales 67 of Zone A. When the circular knitting machine stops
icnitting Zone A and starts knitting Zone B, non-eiasbicized yam 66 is trapped
by
the knitting needle and the same needle releases elasticized yam 69 to knit
Zone
s B. The switch of yam 86 with yam 69 is performed automaticatiy and is
preprogrammed by the oomputer that controls the circular knitting machine. By
automatically switching yam 66 for yam 69, the modulus of elasticity of spacer
fabric 50 Is selectively increased In Zone B. Seteciively modifying the
modulus of
elasticity of the spacer fabric 50 by removing the non-etasticized yam and
introducing the elasticized yam, allows the fabric to be engineered to meet
specific garment or fabrtc crderia.
Spaoer fabric 50 Is shown as incorporatft a single elasticized yam 89.
However, several or a piuraiity of eiasticlzed yarns could be exchanged with
non-
elastiaized yams to create a spacer fabrlc with higher pementage of
elasticized
yams reiative to non etasticized yams. The resultant garment or piece of
fabric
would have a high degree of elasdcity in predetennined regions retatnre to the
non-elasticv.ed or lower elasticizsd regions. More elasttcEzed yarns would
provide greater power to certain types of gannents, for example, shapewear and
athietic wear garments. For example, a covered SpandexTO could be
Incorporated Into the elasttcized zone of the spacer fabric to create a zone
of
enhanced elasticity and control. Furiher, the modulus of elasticity of badcing
layer 70 could also or altemativeiy be niodified to introduce or remove
elast9cized
or non-eiasticized yams to further enhance or reduce the modulus of elasticity
of
spacer fabric 50. Additionaily, by Intermittently and selectively exchanging
eiasticized and non-elasticized yams any number of zones of varied moduli of
elasticity can be Introduced Infio spaoer fabric 50. By modifying the moduEi
of
elastkty in factng surfaces 60 and 70, respedivety, higher levels of power or
reduced levels of power can be achieved in adJacent zones of the spacer fabric
50 than would othenufse be pomble.
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Attemative[y, apacer fabric 50 of the present invention can be circulariy
knitted to form undergarments, such as, for example, a brassiere, panty or a
br9ef, afthough other garments could also be knitted. Further, the relative
thidcness of the spacer layer 80 compared to the facing surfaces 60 and 70,
the
s spacer fabrtc is kiealiy suited as a liner for both brassieres and panties.
Referring to Fig. 6, a circularly knitted seamiess brassiere 110 }s knided
using a spacer fabric 50. Brassiere 110 has a pair of breast-receiving cups
115,
a pair of shoulder straps 125, a tonm-enc9rciing band 130 and side panels 135
io havfng commonly known fasteners to secure brassiere 110 about the torso of
the
wearer. Brassiere cups 115, and torso encinchng band 130 and side panels are
knitted to provide multiple zones of modified elastidty. Breast reoeiving cups
115
have at least two zones of varied control and support. Lower support portion
118
of cup is knitted to have a higher modulus of elastrcity than upper support
portbn
120. Torso-encircling band 130, preferably a tumed welt or a fold region, is
knitted to have high a modulus of eiasticity. Torso-encircling band 130 is
knitted
using preferably 235 den Spandex"" with a singie cover of textured polyester
to
provide a high level of onntrol and support in this zone, although more
powerful
yams could atso be used. Side panels 135 have a low modutus of elasticity to
2o atbw for easy movement of the user during wear. The yams that are knitted
to
form breast-n3ceiving cups 115, torso-encircllng band-130 and side panels 135
are pre-programmed Into the computer of the circular icnitting machine.
uii of
The unique benefit of the spac:er fabnc that has vanable mod
25 etastictty Is that such fabric is or can be engineered accortfing to the
desired
specifications of a garment or a piece of fabric. When a garment is lcnitted
from
spacer fabrtc to Include vartable moduli of elastlcity In crltfcal zones as
needed,
or desired, the finished garment wiil have tfie funcctionality of a art-and-
sew
garment with the aesthetics of a circufarty knit seamiess garment. Thr added
30 support offered by the garment knilted from the spacer fabrSc of the
present
invention may be hidden from view or shown depending upon the desired
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aesthetics for a particular garment or piece of fabric. The finished garme t
has
muitiple zones of variable modu{i of elasWty without additional sewing or
manual steps. Further, the reduction of tfine In making the garment reduces
manufacturing oosts. Additionalty, any iamination steps to provide additionai
s thickness and modesty or support to the garment are also eGcninatsd because
the spacer layer of the garment provides the added thickness and loft.
The spacer fabric of the present inventbn differs from other spacer fabric
in that an indivkiual garment Is knitted having selected regions of eiasadty
in
io predetermined zones. Conventionally, an entire width of spacer fabrtc Is
laiitted
having a uniform elasticity throughout the entire fabric. According to the
present
invention, regions of efastfdty of the spacer fabric are knitted using, for
example,
a pre-pmgrammed circular knitting machine conneaed to a str9per unit to knit a
spacer fabric or gaffr-ent containing a pattem or other desired configuration
of
is elasticized yams.
Aitemativeiy, the spacer fabric 50 of the present invention can have
additional appiicabiiity. Spacer fabric 50 can be used in undergarments, as
for
example a liner, to provide support and coverage and/or modesty to the
20 undergarment. The spaoerfabrfc 50 can be used as.a Mner, by way of example,
in a cup region of a brassiere, a panty or brief to prov(de enhanoed coverage
beneath the outer materiai of the undengarment
Further, the spacer fabric 50 can be knitted using a variety of yarn and
25 stitdy combinations. Refening to Fig. 3, the spac,er fabdc 50 could be
knitted
using a bare spandex In the fabric. To reduce the elastidty or to modify the
elasticPty, textured polyester could be added to reduce the overai'I elasadfy
of the
spacer fabric In critrcaf areas. Additbnaiiy, covered spandex Is preferabfy
introduoed Into spacer fabric to control the moduius of the gamient during
3o kn'itting. The covered spandex preferabty provides differirig levels of
power and
moduius depending upon appitcation. DifFereait count Qpfions, preferabiy 70,
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140,235 and up to and Including 300 den SpandexTM yams with a single cover of
textured polyester. By intnxiucing the different count options in a single
plece of
spacer fabric or a gamient, several power levels can be acti~eved In a single
engineserecf piece of spacer fabric or a gan=nent
The spacer fabric 50 of the present invention is knitted on a circular
knitting machine. The circular knitting rnach)ne preferably has a striper unft
that
Is controlled by a computer that controls the machine. The introduction and
removal yams to create the spacer fabric 50 Is achieved by striper units that
are
io attached or connecfed to the cyilnder of the dreular knitting machlne.
These
units contain appendages that hold separate yams B2, 64, 66 and 68 that are
kndting the fadng layer B0 and backing layer 70, respedively, of the spacer
fabric 50. The movement of the appendages automaticaily trap yams and
release other yams simultaneously to Introduce and remove the desin3d yams to
is thus modify the modulus of elasticity of the spacer fabric 50, as desired.
The unit
appendages are acthrated by computer controls that are pre-programmed fn the
circuiar knitting machine to Introduce or remave the appendages from the
knitting
needles once per revolution.
20 The bcation of 1he yam exchanges can be contratled to provide the
desired eiasticity In varlous locations on the fabric. For eocampie, if a
brassiere
110 is being knftted. side bands 135 could be knitted to Increase the degree
of
eiastictty by tmftiing In elast<ctzed yams whPle non-elastldzed yams are
removed. }
The yams are preferable exchanged in the facing layer 60 and backing layer 70
2s oP the spacer fabric 50.
Spacer fabric 50 can be treated or knitted to add spedflc functionality to a
subsequentiy prroduced gamlent or garment component. - For example, a spacer
fabric 50 can be molded to form breast receiving cups. The resultant cup would
30 not only have regions af varied moduius of elast<city but would also have
the
desired molded shape. In a brassiere, adjacent zones could be knitted having
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differsnt degrees of elasticity. In a pat of pandes, the portion of the
gamient
proximate the stomach could be knitted to have a high modulus of efasticlfy,
while the adjacent regions to have a lower modulus of elasticity. 5 Further,
spacer fabric can be kn+tted to provide an aesthetic complement
to the funcifonal benet}ts of the spacer fabdc or garment knitted with
r
predetermined zones of elasticity. Referring to FJg. 7. a spacer fabric 100
having
a facing surface.105, a bacddng surface 110 and a spacer layer 115, Is shown.
Facing layer 105 is knitted to have a zone 120 having a greater modulus of
elasticity than zone 125. Backing surface 110 has an elasticity lower that
either
zone 120 or zvne 125. Zone 120 is knitted using, for example, a red colored
yam and zone 125 Is knitted using a whtte yam and backing surface is knitted
in
a matte texture.
is Aiternatively, as shown in Fig. 8, spacer fabric 140 has a facing surface
145, a backing surface 150 and a spacer layer 155. Facing surface 145 is
knitted using a decorative pattem, for exampie, a Jacquard pattern with
different
camponents of the design knltted using difierent cotors, wherein ffie
different
coiors represent yams of d(fferant siasficity. Backing surface 150 is icnttted
2a ustng, for exampLe, either a Jacquard of a shtny finish yarns. ln aii
knitting
cornbinations trsing variabie modufus, the e4asticized and non-elasffcized
yams
ana used to create the visuat pattem, of the same or dtffemnt caEor, thus
creating
di!fferent zones of elastlcity. The same dlstinctbn in power between or among
selected zones of variable modulus can atso be made using yams of diffetertt
25 thickness.
For example, a facing layer can be treated to -be de-lusten3d or printed
wPth a desired pattem, In which the pattem is-established using efas8cized and
non-elasticlze yams. R-lternative[y, a facing layer can be knitted with a
Jacquard
30 pattem or have an embroidered pattem thereon, in which the pattem is
knitted
using yams of differfng modufi. Addit(onally, either facfng layer or backing
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can be knitted to have a shiny finish or a matte finish to create a
distinctive visual
appearance in the garment orfabrim Further, either facing or backing layer can
be knitted to have regions of altemating or differing shine or matte regions
or
coiors. Further, the facing layer can be knitted witli three different colors
s represented. Addidonally, the facing layer and the bacidng layer can be
knitted
to have a shiny finish or a matte finish to create a disttnctive visual
appearance
for both sides of the fabric or garment
An irrcrsase in weight or a reduaed weight of ttie spacerfabrfc resu>ts from
io the use of various moduius SpandexTM yams. The increase or reducdon In
weight changes the transparency or opacity of the spacer fabric by modifying
its
density.
While the present disclosure has been described with reference to one or
is more exemplary embodiments, it vtin'K be understood by tfiose skilled In
the art
that various changes may be made and equivalerits may be substituted for
elements theraof wittwut depardng from the scope of the present disclosure. In
addition. many modifications may be made to adapt a partkuiar situation or
material to the teachings of the disdosure without depart[ng from the scope
ao thereof. Therefore, it Is Intended that the present d'isdosure not be
iimited to the
particuiar embodiment(s) disclosed as the best mode contamplated, but that the
disclosure witl include aN embodiments faliing within the scope of the
appended
claims.
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